Line set assembly

ABSTRACT

A line set assembly for a climate control system, includes a first refrigerant line configured to carry a refrigerant, a second refrigerant line configured to carry the refrigerant, a drain hose configured to carry condensate generated by an evaporator of the climate control system, an electrical cable, and an outer sleeve that encases the first and second refrigerant lines, the drain hose and the electrical cable to form an integral unit.

CROSS-REFERENCE

This application claims the benefit of U.S. Provisional Application No. 62/850,706, filed May 21, 2019, the entire disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND 1. Technical Field

The present disclosure relates generally to the field of air conditioning/heat pumps, and more specifically to line sets for air conditioners/heat pumps.

2. Related Art

In the field of air conditioning, there mini-split type air conditioners (i.e. ductless air conditioner evaporators or indoor units). These types of systems use evaporators that generally require four connections: two refrigerant pipes (i.e. a line set), an electrical cable, and a condensate drain.

The line set consists of two copper, aluminum or composite tubes that can vary in diameter according to the size of the evaporator. These tubes are usually both insulated to maintain the correct balance of refrigerant temperatures and to eliminate sweating, thereby ensuring the optimal performance of the evaporator.

The electrical cable is used to connect the condenser, which is an integral part of the air conditioning apparatus, and to which power is supplied from an external source, to the indoor unit. This cable is used both to power the indoor evaporator as well as to provide electronic signals to enable the indoor evaporator to communicate with the outdoor condenser.

The condenser emits hot air while cooling and cold air while heating, and is usually situated outside the building for thermal exchange with the outdoor environment. The condensate outlet, which is supplied with the evaporator can take two forms: (1) in the case of a wall mounted evaporator, a short length of insulated drain hose (usually around 18 inches long) with one end connected to the condensate drain pan inside the evaporator and the other end connected to a drain pipe which directs the condensate produced by the evaporator to a suitable drainage point inside or, more often, outside the building; (2) in the case of an in-ceiling mounted evaporator (commonly known as a cassette), an exposed under ceiling evaporator, or a ducted evaporator, the condensate disposal system may include an internal pump which terminates in a rigid plastic pipe stub to which an external drain hose or drain pipe is connected.

In all cases, the condensate produced by the evaporator in the cooling mode is conducted to a suitable drainage point. For wall mounted evaporators, this drainage point is usually situated outside the building. For in-ceiling mounted evaporators (cassettes), exposed under ceiling evaporators, or ducted evaporators, the drain outlet is usually connected into a drainage system inside the building.

For ease of installation, the most practical method of installation is for the installer to bundle these four items (i.e. two refrigerant pipes, an electrical cable, and a condensate drain) together as one integral assembly so they can be installed with a minimum of labor. In addition, in most parts of the United States, mechanical codes require that any exposed line set be protected from the elements, ultraviolet (UV) light, and physical impact by an external covering which can resist these forces.

In current practice, for the actual line set assembly, the installer has three options available: (1) acquire two single copper pipes, acquire the correct size of insulation sleeve, apply the insulation onto the copper pipes and then assemble them into a line set by binding them together with tape every few feet; (2) acquire two pre-insulated copper pipes and then assemble them into a line set by binding them together with tape every few feet; or (3) use a pre-assembled line set assembly in which the two copper pipes are supplied as one pre-insulated assembly.

The next step would be to attach the cable to the line set assembly, and, in those cases where the drain hose must follow the same course as the line set and cable, this would then be included into the bundle which is secured by taping it every few feet.

Finally, once the assembly has been installed and connected, the installer must install a cover, which may be rigid or flexible, to protect that part of the bundle which is exterior to the building from the elements.

BRIEF SUMMARY

The disclosed embodiments relate to improved line set assemblies for the installation of mini-split (i.e. ductless air conditioner evaporators or indoor units) which are installed on vertical wall surfaces as well as horizontal ceiling surfaces. The disclosed embodiments can also be applied to ducted air conditioning systems which may have different parameters regarding the composition of the line set assembly. Advantages of the embodiments herein include greater ease of installation of the line set. It is advantageous to the installer to be able to acquire a preassembled line set assembly that includes: (a) the line set; (b) the electrical cable; (c) the drain hose; and (d) a covering sleeve. The covering sleeve: (i) consolidates the line set, the electrical cable and the drain hose into one easily manipulated bundle; (ii) prevents the insulation on the line set from being torn or damaged while being threaded through any obstructions in its path from inside the building to the exterior, and (iii) acts as a protective cover to shield the line set, the electrical cable and the drain hose from the elements after installation.

A line set assembly for a climate control system according to some embodiments, includes a first refrigerant line configured to carry a refrigerant, a second refrigerant line configured to carry the refrigerant, a drain hose configured to carry condensate generated by an evaporator of the climate control system, an electrical cable, and an outer sleeve that encases the first and second refrigerant lines, the drain hose and the electrical cable to form an integral unit.

According to some embodiments, the outer sleeve is UV-resistant.

According to some embodiments, the outer sleeve is fire-resistant.

According to some embodiments, the outer sleeve is a plastic material.

According to some embodiments, the outer sleeve is self-fusing silicone tape.

According to some embodiments, the electrical cable is a four-wire cable.

According to some embodiments, the electrical cable is a two-wire cable.

According to some embodiments, the line set assembly includes a four-wire cable and a two-wire cable.

According to some embodiments, the first and second refrigerant lines are insulated tubes.

According to some embodiments, the first and second refrigerant lines are insulated copper tubes.

According to some embodiments, the first and second refrigerant lines include a connector at least at one end of the refrigerant lines.

According to some embodiments, the line set assembly is flexible.

According to some embodiments, a climate control system includes a condenser located outdoors; the evaporated located indoors; an exterior wall separating outdoors and indoors; and the line set assembly penetrating the exterior wall. The first and second refrigerant lines and the electrical cable are connected between the condenser and evaporator. In some embodiments, the climate control system further includes a drainage located outdoors. The drain hose is connected between the evaporator and the drainage.

A method of assembling line set for a climate control system, includes providing a first refrigerant line configured to carry a refrigerant, a second refrigerant line configured to carry the refrigerant, a drain hose configured to carry condensate generated by an evaporator of the climate control system, and an electrical cable. The method further includes, prior to connecting the first refrigerant line, the second refrigerant line, the drain hose, and the electrical cable to other components, encasing the first refrigerant line, the second refrigerant line, the drain hose, and the electrical cable in an outer sleeve to form an integral unit.

The line set assembly can be fabricated in a factory in large coils, e.g. 50 feet, 100 feet, 200 feet, etc., transported to site and cut to length as required. The line set assembly also can be fabricated in a factory in specific lengths, e.g., 10 feet, 20 feet, 50 feet. The line set assembly can be fabricated on a mobile trailer or factory that can be transported to the job site and the optimum lengths to match the specific requirements of each evaporator can be custom made on site. In other words, in some embodiments, the line set is pre-assembled. In some embodiments, the outer sleeve is extruded with the first and second refrigerant lines, the drain hose, and the electrical cable disposed therein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a section of an integrated line set of an embodiment illustrating the components in an assembled configuration.

FIG. 2 is an exploded isometric view of a section of the integrated line set of FIG. 1 illustrating the components in isolation.

FIG. 3 is an isometric view of a section of an integrated line set of an embodiment illustrating the components in an assembled configuration.

FIG. 4 is an exploded isometric view of a section of the integrated line set of FIG. 3 illustrating the components in isolation.

FIG. 5 is a block diagram of a system using embodiments of the integrated line set assembly.

FIG. 6 is a flowchart of a method of assembling the integrated line set of FIGS. 1-5 according to one embodiment.

DETAILED DESCRIPTION

FIG. 5 shows a climate control system 12 using embodiments of the line set assembly 10 described herein. This system 12 is an environment in which embodiments of the line set assembly 10 can be used. Condenser 14 and evaporator 16 are separated by exterior wall 20, resulting in the condenser 14 being outdoors and the evaporator 16 being indoors. In this system 13, the line set assembly 10 connects the condenser 14 and evaporator 16 via refrigerant lines 1 and 2 and electrical cable 3 through the exterior wall 20. Condenser 14 is connected to an external power source 18. The electrical cable 3 can transmit power (originating from power source 18) from condenser 14 to evaporator 16, and transmit communication signals between condenser 14 and evaporator 16. Refrigerant lines 1 and 2 allow for thermal exchange between the condenser 14 and evaporator 16, facilitating either removal or supply of heat to the conditioned space where the evaporator 16 is located. It should be appreciated that depending on the heating and cooling mode of the system, evaporator 16 could perform condensing, and condenser 14 could perform evaporating. The drain hose 4 of the line set assembly 10 moves condensation water from the evaporator to drainage 22 located outdoors.

Referring to FIG. 1, which illustrates a section of an assembled integrated line set 10 (i.e. “line set assembly”) according to one embodiment, the line set assembly 10 includes a first refrigerant line 1 (also sometimes called the “suction line”), a second refrigerant line 2 (also sometimes called the “hot gas line”), an electrical cable 3 (also sometimes called the control line), and a drain hose 4 (also sometimes called the “condensate line”). The first and second refrigerant lines 1 and 2 (collectively referred to as a “line set”), the electrical cable 3, and the drain hose 4 are bound together by covering sleeve 5 (also sometimes called the “outer jacket”). FIG. 2 is an exploded view of the same embodiment showing short segments of the line set assembly 10 including the refrigerant lines 1 and 2, the electrical cable 3, the drain hose 4 and the covering sleeve 5.

According to several embodiments, the line set assembly 10 is pre-assembled. In other words, line set assembly 10 is already in one integral unit before being connected to components of the climate control system 12 (e.g. condenser, evaporator, drainage). This pre-assembly may take place at the site of the climate control system 12, or elsewhere. In either case, the assembly 10 is assembled before the refrigerant lines, electrical cable, or drain hose are connected to e.g. the condenser or other components, and before assembly 10 is routed through exterior wall 20 or other obstructions. This is shown in FIG. 6, where in S60, all of the assembly components are provided prior to being connected components of the system 12. Afterward, in S62, the components are encased in the covering sleeve 5 to form an integral unit. In some embodiments, connectors are connected to one or more ends of the first and second refrigerant lines. This step is also performed prior to connection of the refrigerant lines, electrical cable, and drain hose to other components of the climate control system.

In some embodiments, the refrigerant lines 1 and 2 are copper tubes 1 a, 2 a, that each have a covering of insulation 1 b, 2 b surrounding the exterior of the tubes 1 a and 2 a. The refrigerant lines also can be comprised of aluminum, plastic, or a composite material. The tubes 1 a, 2 a of the refrigerant lines 1 and 2 can be provided with raw ends or can be fitted with flare connectors 1 c, 2 c or any other commercially available quick-connect fitting that may be used in the installation of refrigerant piping. If the line set assembly 10 is provided in a short length (e.g., 5 feet, 10 feet or 20 feet), it may be desirable to provide a connector 1 c, 2 c at one or both ends of the refrigerant lines 1 and 2. If the line set assembly is provided in a long length or roll (for example, 50 feet, 100 feet, 200 feet, etc.), which is more likely to be used for the installation of multiple air conditioners, then it may be desirable to provide the refrigerant lines 1 and 2 without any connectors. The refrigerant lines will be connected between the indoor evaporator and the outdoor condenser of the air conditioning system.

The electrical cable 3 may include four wires, and is required to connect the condenser, which is an integral part of the air conditioning apparatus (and to which power is supplied from an external source) to the indoor unit (i.e. evaporator 16). In many embodiments, the electrical cable 3 is used both to power the indoor evaporator 16 as well as to provide electronic signals to enable the indoor evaporator 16 to communicate with the outdoor condenser 14.

In many embodiments, the drain hose 4 is flexible and made from plastic. The drain hose 4 is usually connected between the condensate drain pan inside the evaporator 16 and a drain pipe which directs the condensate produced by the evaporator to a suitable drainage point 22 inside or, more often, outside the building.

In the embodiment of FIGS. 1 and 2, the refrigerant lines 1 and 2, the electrical cable 3, and the drain hose 4 are encased by an outer sleeve 5 and thus provided as one pre-fabricated line set assembly 10. Using this assembly, an installer can avoid: (1) separately obtaining the individual refrigerant lines (or a preassembled line set consisting of only the two refrigerant lines), the electrical cable, and the drain hose; and (2) individually installing the refrigerant lines, electrical cable, and drain hose or taping (or otherwise binding) them together into an assembly before installation. The sleeve 5 also prevents the refrigerant lines 1, 2, the electrical cable 3, and the drain hose 4 becoming caught on obstructions during the installation process, which sometimes involves pushing the assembly through holes in walls, ceilings and/or floors, and/or through long passageways. If the sleeve 5 is made from a UV-resistant material, the sleeve also protects the inner components (the refrigerant lines 1, 2, the electrical cable 3, and the drain hose 4) from exposure to the elements with respect to any portion of the assembly that is located outdoors.

The flexible outer sleeve 5 can be made from any material (including plastic, fabric, or metal) that provides the properties of flexibility, weather resistance, and low friction. The sleeve also can be made from a fire-resistant material. The outer sleeve 5 can be shrink-wrapped onto the inner components (the refrigerant lines 1, 2, the electrical cable 3, and the drain hose 4) along the entire length of the line set assembly except near the ends as shown in FIG. 1. Rather than shrink-wrapping, the outer sleeve 5 can be extruded simultaneously around the inner components, spirally wrapped around the inner components or applied by any other method which enables the sleeve 5 to be applied to the exterior of the inner components (preferably in production quantities). Some specific materials for the sleeve 5 include but are not limited to: polystyrene, polyethylene, any polymer or film, cloth or impregnated cloth or tape, nylon, rubber, vinyl, self-fusing silicone tape, or any combination thereof.

The line set assembly can be fabricated in a factory in large coils, e.g. 50 feet, 100 feet, 200 feet, etc., transported to site and cut to length as required. The line set assembly also can be fabricated in a factory in specific lengths, e.g., 10 feet, 20 feet, 50 feet. The line set assembly can be fabricated on a mobile trailer or factory that can be transported to the job site and the optimum lengths to match the specific requirements of each evaporator can be custom made on site.

FIG. 3 and FIG. 4 are views similar to FIGS. 1 and 2, respectively, of another embodiment. This embodiment is similar to the previous embodiment but adds communication wire 6, which in this example is a two-wire shielded pair communication line. The two-wire communication wire is, for example, an 18 gauge two conductor twisted/shielded communication wire. Such communication wires 6 are used for certain installations in addition to, or instead of, the four-wire electrical cable 3. As the cost of the four-wire cable 3 and the two-wire cable 6 each are relatively low, it is cost effective to provide both of the cables 3 and 6 in the line set assembly even if only one of the electrical cables is needed for some installations, so that different line set assemblies do not need to be on hand.

Various modifications are possible. For example, the outer sleeve 5 can contain any number of line set assemblies. For example, the line set(s) can consist of any combination of pipe sizes and/or thicknesses of insulation. For example, the line set(s) can be plain, insulated or partially insulated. For example, the insulation can consist of any insulation material or any combination of different insulation materials. For example, the line set assembly can consist of a refrigerant line set only. For example, the line set assembly can consist of a refrigerant line set with a drain hose or a plurality of drain hoses. For example, the assembly can consist of a refrigerant line set, a drain hose and an electrical cable or a plurality of electrical cables. For example, the line set assembly can be scalable in that it can be expanded to include any number of line sets, drain hoses and electrical cables in any combinations.

Although the invention has been described with reference to embodiments herein, those embodiments do not limit the scope of the invention. Modifications to those embodiments or different embodiments may fall within the scope of the invention. 

What is claimed is:
 1. A line set assembly for a climate control system, the line set assembly comprising: a first refrigerant line configured to carry a refrigerant; a second refrigerant line configured to carry the refrigerant; a drain hose configured to carry condensate generated by an evaporator of the climate control system; an electrical cable; and an outer sleeve that encases the first and second refrigerant lines, the drain hose, and the electrical cable to form an integral unit.
 2. The line set assembly of claim 1, wherein the outer sleeve is UV-resistant.
 3. The line set assembly of claim 1, wherein the outer sleeve is fire-resistant.
 4. The line set assembly of claim 1, wherein the outer sleeve is a plastic material.
 5. The line set assembly of claim 1, wherein the outer sleeve is self-fusing silicone tape.
 6. The line set assembly of claim 1, wherein the electrical cable is a four-wire cable.
 7. The line set assembly of claim 1, wherein the electrical cable is a two-wire cable.
 8. The line set assembly of claim 6, further comprising: a second electrical cable that is a two-wire cable, wherein the outer sleeve encases the second electrical cable.
 9. The line set assembly of claim 1, wherein the first and second refrigerant lines are insulated tubes.
 10. The line set assembly of claim 9, wherein the first and second refrigerant lines are insulated copper tubes.
 11. The line set assembly of claim 1, wherein the first and second refrigerant lines each include a connector at least at one end thereof.
 12. The line set assembly of claim 1, wherein the line set assembly is pre-assembled.
 13. The line set assembly of claim 12, wherein the outer sleeve is extruded with the first and second refrigerant lines, the drain hose, and the electrical cable disposed therein.
 14. The line set assembly of claim 1, wherein the line set assembly is flexible.
 15. A climate control system comprising: a condenser located outdoors; the evaporated located indoors; an exterior wall separating outdoors and indoors; and the line set assembly of claim 1 penetrating the exterior wall, wherein the first and second refrigerant lines and the electrical cable are connected between the condenser and evaporator.
 16. The climate control system of claim 15, further comprising: a drainage located outdoors, wherein the drain hose is connected between the evaporator and the drainage.
 17. A method of assembling line set for a climate control system, comprising: providing a first refrigerant line configured to carry a refrigerant, a second refrigerant line configured to carry the refrigerant, a drain hose configured to carry condensate generated by an evaporator of the climate control system, and an electrical cable; and prior to connecting the first refrigerant line, the second refrigerant line, the drain hose, and the electrical cable to other components, encasing the first refrigerant line, the second refrigerant line, the drain hose, and the electrical cable in an outer sleeve to form an integral unit.
 18. The method of claim 17, wherein the outer sleeve is UV-resistant.
 19. The method of claim 17, wherein the outer sleeve is a plastic material.
 20. The method of claim 17, wherein the outer sleeve is self-fusing silicone tape. 